WELCOME

HBL NIFE POWER SYSTEMS LTD, Hyderabad

Presentation

onIntegrated Power Supply (IPS)

By

26/08/2005

IPS SYSTEM.

IPS SYSTEMCONSISTS

OF

BATTERYSMR

MODULES+SCU

ASM PANEL

INVERTERS

DC TO DC CONVERTERS

CVT’S +TXRS

RDSO AMENDMENTS FOR IPS

• RDSO/SPN/165/2000,Ver1.0• AMD-1:INCLUSION OF TESTS & CLAUSES CORRRECTION.• AMD-2:INCORPORATION OF LIGHTNING,

SURGE DEVICES & I/P AC CURRENT LIMITING BY REDUCING THE BATTERY PATH CURRENT LIMIT

• RDSO/SPN/165/2004,Ver2.0• AMD-1:MODOFICATION OF NOMINCLATURE• AMD-2:MODIFICATION IN TEMP.,CYCLIC,DRY HEAT &

COLD TESTS.• AMD-3:DELETED THE FAIL SAFETY TEST.(CL. NO:9.2)• AMD-4:IN CORPORATION OF VERSION CONTROL OF

ELECTRONIC SIGNALLING EQUIPMENTS. AS PER ANNEXURE:VI

The DC-DC converter for Axle Counters, SSI and Data loggers are Optional. Purchaser has to specify whether Optional DC-DC converters are required or not. In all cases, the distribution Cabinet shall have provision for

accommodation of optional DC-DC converters

S.M panel consists of status indications and critical alarms of IPS to be provided in ASM’s room. The monitoring panel shall be of wall mounting type. DC-DC converters for block tele may also be accommodated in ASM monitoring Panel .

A set of spares shall also be supplied along with IPS as per Annex.III .All the spare modules shall be accommodated in the IPS rack as Cold standby. Other spares shall be supplied along with IPS and shall be placed with IPS in asuitable bag/box.

The individual cabinets shall be within the Over all dimensions of 2000(H) X 750(D) X 750(W).In case all DC-DC Converter modules cannot be accommodated in one DC distribution panel, then a second DC distribution panel shall be provided instead of making over sized panel.The height and depth of all cabinets shall be of equal size.

RDSO SPEC.DIFFERENCES BETWEEN Ver 1.0 & Ver 2.0

ThePrinted circuit Board shall generally confirm to relevant provisions of latest RDSO/SPN/144 for safety & reliability requirement of

Electronic signaling equip.

Every Alarm condition shall be accompanied with audio alarm with auto cut off after 120 seconds. Provision shall be made for stopping the audio alarm with a push button switch.

The inverter shall be protected against overloaded and short circuit with auto reset facility. Whenever the failure conditions persists, it shall trip and restart automatically after about 10 – 20 sec. But if the problem still persists, the protection shall be permanently get latched and inverter shall not be switched ON again unless the fault is cleared followed pressing of reset push button switch. Inverter overload indication shall appear at 110% of rated load.

The following LED indications shall be provided on front panel of inverter a) Mains ON – Amber b) Output OK – Green c) Inverter fail - Red

d) Inverter ‘ON load' – Green e) Fan fail indication - Red (In case of forced cooling)

 The inverter shall be capable of delivering 125% of rated full load for a period of 24 hours.It should be capable of delivering 200% of the rated full load for a period of 300 ms in order to cater for the high in-rush current at the time of

switching ‘ON’ of the inverter

The overall efficiency of the DC-DC conv.at full load shall not be less than 75% converters rating from 50VA to less than 150VA at rated load and 80% for

converters of 150VA or more rated output at 98V to 138V of nominal input voltage. . For converters of rating 10VA –50VA, overall efficiency shall be greater than 50%. The efficiency shall be measured at the maximum

output voltage of the specified range.

The DC-DC converter for relay internal and relay external is catered for 24V, 5A operated metal to carbon relays. For 60V operated metal to metal relay system,DC-DC converter shall be used in n+2 configuration for relay internal. Where 'n' is the number of converters required to cater actual current requirement.

Railway

shall specify the rating of DC-DC converter as under:

Relay internal 60-66V, 5A (n+2) Relay external 60-66V, 5 A (n+1)

Relay external 24-32V, 5A (n+1)

The output ripple (peak to peak) of the converter shall not be more than 50mV at full load.

The ASMpanel shall have following LED indications and alarms with resetting switch:a) START GENERATOR b) EMERGENCY START GENERATOR c) SYSTEM SHUT DOWN d) CALL S&T STAFF e)

STOP GEN.SET

SOURCE OF

DISTURBANCE

SPECIFIED

(TEST CONDITION)

REALITY

IN FIELD

1 INPUT AC VOLTAGE

150VAC – 275VAC

SEVERE HUNTING BETWEEN 140-170 SOME TIMES FURTHER LOW. SOME TIMES HIGHER THAN 275.

2 a)WEAK SOURCE`

b) D.G.SET

REGULATION POOR

NIL HIGH SOURCE IMPEDANCE LEADING TO HEAVY DROP IN INPUT VOLTAGE LEADING TO SYSTEM CHATTERING / HUNTING EVEN WITH SMALL LOADS.

D.G.SET REGULATION OBSERVED MORE THAN 15% AND VOLTAGE GOING BEYOND THE 275V AC EVEN AT 5 A TO 10 AMPS LOAD.

3 LIGHTING ARRESTERS

1) CLASS “B”

2) CLASS “C”

NO TEST AVAILABLE TO CHECK THE CAPABILITY DUE TO INHERENT PROHIBITIVE HIGH COSTS. EVEN THIS WILL NOT PROTECT IF EARTHING IS IMPROPER AND BUILDING IS NOT PROTECTED.

FIELD FAILURE ANALYSYS

Sl.No

MOD Description of failure

Nature of failure observed

Reason for failure observed

Corrective/Preventive action Recommended

01 SMR 1. Power supply card failure.

1. In put capacitor C20 Failing,

2. TOP249N switch fail.

Due to Input High voltage fluctuation in the supply.

--do--

1)Modified the100μf / 400VDC Capacitor to100μf / 450VDC

2) Resettable fuse to be connected in series with Line supply wire of the Power supply card (CN4-3 pin ferrule no :3)

02 SMR 1. Relay card failure.

1.Failure of Relay card due to burning of MOVs

MOVs across line to earth and Neutral to earth failing due to improper earthing

1.MOVs MOV2&MOV3 to be removed.

2.C3&C6 are to be changed from 1 μf/ 400VDC to 0.1μf/ 275VAC

Sl.No

MOD Description of failure

Nature of failure observed

Reason for failure observed

Corrective/Preventive action Recommended

03 SMR 1.Control card failure.

 

U7 &U13 are failing in control card

Mains fails and restoring time if SCU is in boost mode these ICs are failing due to –ve voltage occurring to this ICs.

D-type connector card modified to avoid the –ve voltage during mains fails and restoring time.

04 SMR

RACK

SMR Modules are hunting during getting ON D.G.Set

BPCL Increasing initially

Input feeder Capacity/ D.G.Set regulation problem/very poor

Hall probe to be implemented in Battery Path

Sl.No

MOD Description of failure

Nature of failure observed

Reason for failure observed

Corrective/Preventive action Recommended

05 DC/DC Converter

Module failure

Module fail due to high output voltage

Due to Voltage adjustment by field personal at site by more than acceptable limits

Voltage adjustments will not be done beyond the specified limits

06 SCU Mod.

MOBD alarm

Alarm display in only LMLA battery sites

Due to LMLA battery, MOBD alarm is displayed as a fault, whenever battery changes form boost to float mode

In order to correct, the MOBD alarm delay has to be increased

IMPROVEMENT BENEFIT

Short circuit Auto recovery provided .If short persists continuously inverter will latch

Inverters automatically restores even Accidental short circuit occurs at site.

Auto reset switch provided To start the inverter with out interruption of Input MCB during Inverter Latch Condition

Auto cut-off Audio alarm facility provided in Supervisory Control Unit(DSA-Distribution Supervisory Control Alarm) Unit

To avoid unnecessary Interruption audio alarms.

Spare modules provided in the rack itself Ready availability of spares at the site

Stop Gen Set” Indication provided on ASM Panel. Alert the Maintenance people to

switch OFF the D.G.Set.

STATIC SWITCH AT INPUT TO THE SMR RACK IT IMPROVES IPS SYSTEM PERFORMANCE BY REDUCING THE SMR FAILURES DUE TO HIGH VOLTAGES AND FLUCTUATIONS.

Improvements Made In IPS System To meet the requirements of new Spec (RDSO/SPN/165/2004 Ver.2)

Improvements Made by HBL-NIFE In IPS System

IMPROVEMENT BENEFIT

SMR & Inverter Modules are re engineered Size and Weight reduced

For easy Maintenance and serviceability

SMR Input Current Limit To avoid Input Voltage hunting due to week input feeder.

SCU(Supervisory Control Unit) Panel No.of PCB’s reduced from 6 cards to 2 cards (IN V2A)

To Improve System reliability

Rack level control wiring changed from discrete type connectors to FRC (Flat ribbon Cable) connectors.

To avoid wrong connections in the field.

THANK YOU